Amplifier and detector bulb and process of making the same



Nov. 19, 1929. e. H. PERRYMAN 1,736,275

AMPLIFIER AND DETECTOR BULB AND PROCESS OF MAKING THE SAME 2 Sheets-Sheet 1 7 I x H In Filed Nov. 1, 1924 lrl I II I II Nov. 19, 1929. a. H. PERRYMAN Q AMPLIFIER AND DETECTOR BULB AND PROCESS OF MAKING THE SAME l 2 Sheets-Sheet 2 Filed Nov. 1, 1934 ril IIIIIIIIIIII Ill 1 NVENTOR My TI'ORNEYS Patented Nov. 19, 1929 l I GEORGE HENRY PERRYMAN, OF WEST NEW YORK, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGNMENTS, TO PERRYMAN ELECTRIC 00., INC., A CORPORATION OF DELAWARE bling the various parts.

' spoiled during AMPLIFIER am) nE'rE-oron BULB AND rnocnss or MAKING THE sAiuE Application filed November 1, 1924. Serial No. 747,1ea

This invention relates to bulbs and especially to amplifier or detector bulbs used, for in stance, in radio sets. '1 I v The object of the invention is to provide a bulb which will be simple and durable in construction. A further object of the invention is to provide a process for manufacturing bulbs which process will be rapid in operation and economical in cost. 1

The main factors in maintaining a high cost of production of amplifier and detector bulbs are their complicated construction and the hand labor used in forming and assem- The delicate, intricate construction of the usual bulb parts and the large amount of handling required cause a large percentage of the bulbs to be manufacture with resultant increase in cost;

7 With the bulb and process of this invention the parts are simple in form and assembly reducing the waste during manufacture and at the same time giving a sturdy durable construction to the bulb as a whole.

. In the accompanying drawings illustrating the invention Fig. 1 is an elevational' view of a bulb.

Fig. 2 is a planview of the electrode of the same.

Fig. 3 is a vertical section on the line 3-3 of Fig. 1 Fi 3 is a horizontal section on the line 3 -3 Fig. 1. a I

I Fig. 4 is a diagrammatic elevational view illustrating the assembly of the bulb un1ts.

Fig. 4 is a detail sectional view illustratmg the assembly of the filament element with relation to the other parts.

Fig. 5 is a vertical sectional view showing the elements in assembled position, and

Fig. 6 is a section on the line 66 of Fig. 5.

In the specific embodiment of the invention shown in the drawings a central tubular support 10 of glass has passing through it the filament leads 11 and 13 and the plate and grid leads 12- and 14. The filament lead 11 extends upward above the end of the plate 15 and from the end of the lead ll exte'nds a fine wire support 16 connected by bent clamp 16' to'the inner end of the filament 17 which filament passes downward through the center art.

of thegrid 18 and is connected to the inner I end of the other filament lead 13. The plate 15 of generally cylindrical form is fastened by side fins 15" to the plate lead 12, the platev surrounding the grid and filament elements.

In the final form of the bulb all of these elements are contained'within an outer glass shell20 indicated by broken lines the interior of the bulb being practically entirely .ex-JI hausted. i '60 The wire leads 11, 12,13 and 14 extend upward within the bulb on substantially straight llne's and are continuous from the tube 10 to the elements which they support and are without intermediate breaks or bends that is the wire 11 extends straight up to the cross wire 16 and similarly the wire 13 extends straight up to the lower end of the filament end of the cross wire 16. The supporting wire 12 for the plate also extends straight upward between the'attached fins 15 and the support 14. for the grid extends straight upward within the plate. All of these supports 11, 12, 13 and 14 are thus arranged in succession across the tube in the same general plane. Y

' This gives a very simple andcompact arrangement without the complicated bends and multiplied connections of prior bulbs. This simphcity alsomakes the bulb of this invention more sturdy and durable and able to resist shocks and at the same time is capable of production and assembly at relatively low cost due tothe absence of intricate and delicate connections characteristic of the prior In prior processes of making bulbs it has been usual to form the tube part 10 with the Various lead wires and then to mount on these wires the plate, grid and filament elements. In the process of this invention this rocedure is reversed and the plate, grid an filament elements are first mounted on the supporting wires 12, 13 and 14 and then these parts are assembled as a unit with the tubelO. V The prior procedure required a very delicateseries of operations in which the mounting of the various elements in succession was attended with the' greatest difiiculty due to the fact that the other elements or their supports were 10c in the way and had to be allowed for. Ac-

cording to my method of construction all this is avoided and the interior late, grid and filament elements are assem led to ether and mounted as a unit within the tu e 10 so as to practically eliminate all the subsequent troublesome and wasteful operations.

In the process of my invention as illustrated in Figs. 4 to 6 the various bulb elements are assembled together upside-down in a chuck or support wluch receives and holds them in their proper relation whlle the end of the tube 10 is melted around the supporting wires so as to definitely fix them in'their proper relative positions. Referring to Fig. 4 the various elements are shown in posltlon to be inserted in the chuck 21 below. The filament lead 11 with its extension 11 is. to the left. To the right of this is the plate lead 12 to which'the plate 15 is already attached by the welding of its fins 15' to the lead 12, the end of which is extended by the wire 12'. The helical gridwire 18 is connected to its lead 14 by welding of each of its convolutions to the lead 14 at the point of contact as indicated, the end of the lead 14 being extended as the wire 14'. The filament 17 is suspended from its supporting lead 13 the other end of which is extended as a wire I 13 is dropped down throng 13'. These elements may be conveniently asseinbled in the chuck 21 in the order shown,

.first dropping the wire 11, 11' into place and then the unit formed by the wire 12, 12'- in plate 15 and then the grid 18 with its wire 14, 14' is dropped within the plate and then the filament 17 with its supporting wire 13,

' thegrid, assembled position of the elements in the chuck 21 being shown in Figs. 5 and 6.

The chuck shown in the 'drawin comprises a block or body portion 22 o generally cylindrical form having a deeply bored recess 23 for "the filament lead 11. On the other side thebloek .22 has a bore 30 to receive concentric tubes .24 and 25, the tube 24 has its upper end 26 reduced to fit ;.easily within the plate 15. The innermost tube 25 has its upper end 27 reduced to fit within the grid 18 with its supporting lead 14 and this tube 25 with the annular shoulder 33 of the tube 24 tapered at its lower endto a reduced neck 36 large enough to easily pass the filament 17 but too small to pass the wire 13, this reduced neck portion being positioned so as to properly locate the filament with relation to the grid. Below the neck 36 the bore of the tube 25 is widened out as indicated at 37. so that the filament 17 hangs freely therein. To aid in inserting the fine hair-like filament in the central bore a, tube. 38 isprov'ided as indicated in Fig. 4", thebore of thls tube easily receiving the wire 13 inserted through the J lower end of the tube and drawn into the tube far enough to position the filament 17 entirel within thistube 38; The tube 38 is then p aced in position in the expanded upper end of the tube 25 as shown and lightl tapped so that the wire 13 and filament 1; will drop lightly by gravity into the positionshown in Fig. 5, the entering end of the.fila- 'ment being smoothly guided by the graduall tapered surfaces so that it will not catch or end.

It is obvious that while a certain hence of insertion of the various elements Im the 14 by a clamp or series of clamps. or in any dth'er desired manner and these bulb elements thus joined together as aunit may then be worked into place in the bulb asa unit. In the process of this invention, however, the bulb elements thus assembled and held in the chuck are directly mounted in the gla's tube support 10 by and 14 therein. r

As shown in Fig. 5 the glass tube is inserted over the upwardly protruding wires- 11, 11', 12, 12', 13, 13', 14, 14, in proper spaced relation to the chuck and its contained elements and the lower end of this tube is heated and pressed from each side so that it is flattened and fused solidly around the wires, as shown in Figs. 1 to 3.

In the practice of the process where a large number of bulbs are to be made it will be used to mount a number of chucks 21 on a moving part such as a rotatable table carry ing the bulb parts around through a series of assembling and heating and operations, the various bulb elements being assembled in the chuck 21 after which the glass tube 10 is moved to the position shown in Fig. 5 and then heated and fused and pressed on to the wire leads. During the fusingoperation theend of the exhaust tube 40 becomes fused in the tube 10 and the 0 ening to the interior of the bulb through this tube 40 is blown by' a heated jet directed against the molten glass. When the glass parts have become sufliciently cool they are removed carrying with them the bulb elements and the glass parts are,then annealed-b a very gradual reductionintemperature. fter the annealing the tubular support 10 w1th the bulb elements is removed and the cross wire 16 is welded in place between the lead 11 and the projecting end of the filament 17. The central tubular support 10 with its assembled elements is then inserted and fused into the glass bulb indicated by broken lines in Fig. 1 and the completed bulb fastened in its place in any desired manner, the wire leads 11', 12, 13 and 14' being carried down and connected with the terminals of the bulb base. After the fusing of the lead wires in the tubular support 10 but one simple operation remains involving only the welding of the cross wires 16 between the exposed ends of the filament and lead 11. After this the tubular support 10 is fused into the outer bulb where all of the parts are in fully protected position. There is, therefore, very little handling of the bulb elements and loss by breakage and the development of defects is greatly reduced. This direct assembly of the bulb elements and lead wires and the fusing of these elements as a unit in the tubular support involves also a great saving in the time and labor involved in the manufacture of the bulb over the prior prac-- tics of adding the bulb elements to the leads after the latter had been fused into the tubular support.

The arrangement of the elements as shown brings thefilament lead 11 and plate lead 12 close together on one side while the other filament lead 13 and the grid lead 14 are paired close together on the other side leaving a relatively wide space between the plate lead 12 and the filament lead 13 and this is advantageous in leaving plenty of room for the exhaust tube 40 at the center. The assembling of the bulb elements as a unit also permits the plate and. grid and filament to be positioned very closely to the end of the tubular support 10, the plate 15 with its contained grid and filament being spaced from the end of said support a distance less than the longest lateral dimension of said plate. In prior practice it has been necessary to space the tube elements a greater distance from the tubular sup ort in order to provide room for working t e late, grid and filament into place on the assem led leads.

The piece of magnesium 41 for finally exhausting the tube of oxygen is fastened'in place between the fins 15" of the plate and after the bulb is completely assembled and exhausted and the exhaust tube 40 sealed the plate 15 is heatedto the ignition point of this magnesium which burns and removes the last traces of oxygen within the bulb.

In the structure of this invention this magnesium is very simply and strongly fastened in place in the plate between the, fins 15 so that no extensive extra assembly operation is necessary and there is no danger of this magnesium becoming disconnected before it' hook 16 being formed to receive the filament and then to be compressed against it. The

filament is thus positioned and retained without being welded at any point.

The bulb of this invention is adapted for various sizes and in particular for a small size bulb such as Mag-natron D. C. 199, the total length of the bulb as shown in Fig. 1 being less than, three inches.

- I claim: 7 y 1. The process of providing an'element for an amplifier or detector bulb comprising first fastening said element to its supporting lead wire, and then fastening said lead in supportlng position in the lass, of said bulb.

2. The process 0 providing a plate for an amplifier or detector bulb comprising first fastening said plate to its supporting lead wire and then fastening said lead in supportin'g position in the glass of said bulb.

3. The-process of providing a grid for an amplifier or detector bulb comprising first fastening said grid toits supporting lead wire and then fastening saidlead in supporting position in the glass of said bulb.

4. The process of providing a filament for an amplifier or detector bulb comprising first fastening the said filament to its supporting lead wire and then fastening saidlead in supportin position in the glass of said bulb.

- 5. T e process of providing plate and grid elements for an amplifier or detector bulb comprising first fastening said plate and grid to their supporting lead wires, and then fastening saidlead wires in supporting position in the lass of said bulb.

6. T e process of providing a grid and filament for an amplifier or detector bulb comprising first fastening said grid and filament to their supporting lead wires, and then faselements to their supporting lead wires and then fastening said lead wires in supporting position in the glass of said bulb.

9. The process of making the electrical ele- -ments of an amplifier or detector bulb comprising assembling the plate, grid and filament elements having their supporting leads fastened thereto in proper spaced relation to each other and subsequently fixing said elements in said relation by fastening their supporting leads in fixed position with rela-' tion to each other.

10. The process of making the electrical elements of an amplifier or detector bulb comprising assembling the plate, grid and filament elements having their supporting leads fastened thereto in proper spaced relation to each other and subse uently fixing said elements in said relation y fastening their supporting leads in fixed position with relation to each other in the glass of said bulb.

11. The process of making the electrical elements of an amplifieror detector bulb comprising assembling the plate and grid elements having their supporting leads fastened thereto in proper spaced relation to each other and subsequently fixing said elements in said relation by fastening their supporting leads in fixed position with relation to each other. i

V 12. The process of making the electrical elements of an amplifier or detectorbulb comprising assembling the plate and filament ele- 4 ments having their supporting leads fastened thereto in proper s aced relation to each other and subsequently xing said elements in said relation by fastening their supporting leads in fixed position with relation to each other.

13. The process of making the electrical elements of an amplifier or detector bulb comv prisinglassembling the grid and filament ele-- ments aving their supporting leads fastened thereto in proper spaced relation to each other and subsequently fixing said elements in said relation by fastening their supporting leads in fixed position with relation to each other.

GEORGE HENRY PERRYMAN. 

